Plant maintenanace method and apparatus

• US 20030191606A1
• Filed: 04/09/2003
• Published: 10/09/2003
• Est. Priority Date: 04/09/2002
• Status: Active Grant

• Current Assignee: Kabushiki Kaisha Toshiba (Toshiba Corporation)
• Original Assignee: Kabushiki Kaisha Toshiba (Toshiba Corporation)
• Inventors: Kichise, Hitoshi, Okazaki, Mitsuyoshi, Iwahashi, Takayuki, Asatsu, Seiichi, Fujiyama, Kazunari, Hirasawa, Taiji, Saito, Kazuhiro, Nagai, Satoshi, Harada, Shigeru, Fujiwara, Toshihiro, Minowa, Masanori, Kodama, Hirotsugu, Ishii, Fumiharu, Sudo, Mamoru
• Granted Patent: US 6,928,391 B2
• Time in Patent Office: Days
• US Class Current: 702/185
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling

Abstract

Entered in a plant-maintenance apparatus are data on inspection, diagnosis, repair and operation histories for equipment that constitute a plant to be maintained. Failure-event tree breakdown is performed on failures to be expected for the equipment. Predicted is unreliability of at least one starting item in the failure-event tree breakdown. Unreliability of each item in the failure-event tree is calculated based on failure unreliability function. Unreliability and a cost of recovery from each failure event in the failure-event tree are multiplied and results of the multiplication are accumulated in accordance with the tree breakdown, thus obtaining a recovery cost. Preventive maintenance expenses are calculated for preventing failure events. Maintenance timing and technique are decided through comparison between the recovery cost and the preventive maintenance expenses. Instead of the failure-event tree breakdown, efficiency and operational-function decay event-tree breakdown may be performed on efficiency and operational-function decay factors to be expected for the equipment. Predicted in this case is unreliability of at least one starting item in the efficiency and operational-function decay event-tree breakdown. Unreliability of each item in the efficiency and operational-function decay-event tree breakdown is calculated based on failure unreliability function. Further calculated is efficiency and operational-function decay to be expected from the calculation based on the failure unreliability function. Unreliability and monetary loss due to efficiency and operational-function decay and a cost of recovery from the decay are multiplied and results of the multiplication are accumulated in accordance with the efficiency and operational-function decay-event tree breakdown. Preventive maintenance expenses are calculated for preventing the efficiency and operational-function decay.

Claims

1. An apparatus for maintaining plant equipment comprising:

an input unit configured to receive data on inspection, diagnosis, repair and operation histories for an equipment that constitute a plant;

a failure-event tree breakdown unit configured to perform failure-event tree breakdown on failures to be expected for component parts of the equipment, in order to obtain a failure-event tree;

a probabilistic life assessment unit configured to predict unreliability of a starting event in the failure-event tree;

a failure-unreliability function calculation unit configured to calculate unreliability between items in the failure-event tree;

a failure-derived monetary loss calculation unit configured to multiply each unreliability and a cost of recovery from each failure-event in the failure-event tree and accumulate results of the multiplication in accordance with the failure-event tree breakdown, thus obtaining a recovery cost;

a preventive-maintenance expense calculation unit configured to calculate preventive maintenance expenses for preventing failure events; and

a maintenance decision-making unit configured to decide maintenance timing and technique through comparison between the recovery cost and the preventive maintenance expenses.

2. The apparatus for maintaining plant equipment according to claim 1, wherein the failure-event tree breakdown unit has a failure-event tree database constructed based on inspection and operation histories for the plant to be maintained and other plants, the failure-event tree breakdown unit is configured to perform the tree-breakdown starting with life-assessment candidate items while referring to the database in accordance with data on parts of the plant equipment and events input via the input unit, the apparatus further comprising a diagnostic item selection unit to select an item to be diagnosed for life assessments as input data or a starting event in the failure-event tree.

3. The apparatus for maintaining plant equipment according to claim 1, further comprising a degradation and damage measurement unit having a hardness measurement unit for measuring degradation and damage to the equipment, a replication and microstructural measurement unit and an embrittlement measurement unit for electrochemical measurements, the probabilistic life assessment unit calculating life probability distribution, as the unreliability, covering occurrence of cracks and damage to equipment parts from material-life probability distribution and variation in probability of operational requirements including temperature and stress applied to the equipment parts, based on data stored in a statistical life assessment database constructed of data from the degradation and damage measurement unit and also experimentally-obtained and statistically-processed data on material life.

4. The apparatus for maintaining plant equipment according to claim 1, wherein the failure-unreliability function calculation unit has a failure-unreliability function database constructed based on inspection and operation histories for the plant to be maintained and other plants, the failure-unreliability function calculation unit configured to calculate the unreliability while referring to the database based on failure-unreliability function on each event in the failure-event tree in accordance with information on parts of the plant equipment and events input via the input unit, and the failure-unreliability function calculation unit is also configured to calculate unreliability of life diagnostic items based on the prediction by the probabilistic life assessment unit.

5. The apparatus for maintaining plant equipment according to claim 1, wherein the failure-event tree breakdown unit and the failure-unreliability function calculation unit configured to adjust the order of events in the failure-event tree and failure-unreliability function values in accordance with input data on inspection, diagnosis, repair and operation histories for the plant and other plants and the prediction by the probabilistic life assessment unit.

6. An apparatus for maintaining plant equipment comprising:

an input unit configured to receive data on inspection, diagnosis, repair and operation histories for equipment that constitute a plant;

an efficiency and operational-function decay-event tree breakdown unit configured to perform efficiency and operational-function decay-event tree breakdown on efficiency and operational-function decay factors to be expected for the equipment, in order to make an efficiency and operational-function decay-event tree;

an efficiency and operational-function decay parameter assessment unit configured to predict unreliability of at least one starting item in the efficiency and operational-function decay-event tree;

an efficiency and operational-function decay unreliability calculation unit configured to calculate unreliability of each item in the efficiency and operational-function decay-event tree based on failure unreliability function;

an efficiency and operational-function decay prediction unit to calculate efficiency and operational-function decay configured to be expected based on prediction by the efficiency and operational-function decay unreliability calculation unit;

an efficiency and operational-function decay derived monetary loss calculation unit configured to multiply each unreliability and monetary loss due to efficiency and operational-function decay and a cost of recovery from the decay and accumulate results of the multiplication in accordance with the efficiency and operational-function decay-event tree breakdown;

a preventive-maintenance expense calculation unit configured to calculate preventive maintenance expenses for preventing the efficiency and operational-function decay; and

an operation and maintenance decision-making unit configured to decide maintenance timing and technique through comparison between the recovery cost and the preventive maintenance expenses.

7. The apparatus for maintaining plant equipment according to claim 6, wherein the efficiency and operational-function decay-event tree breakdown unit has an efficiency and operational-function decay-event tree database constructed based on inspection and operation histories for the plant and other plants, the efficiency and operational-function decay-event tree breakdown unit is configured to perform the tree breakdown starting with at least one efficiency and operational-function decay assessment item while referring to the database in accordance with data on parts of the plant equipment and events input via the input unit, the apparatus further comprising a diagnostic item selection unit configured to select the efficiency and operational-function decay assessment item as input data or a starting event in the efficiency and operational-function decay-event tree breakdown.

8. The apparatus for maintaining plant equipment according to claim 6, further comprising an efficiency and operational-function decay parameter measurement unit for measuring degradation of and damage to the equipment to cause efficiency and operational function decay, the efficiency and operational-function decay parameter assessment unit is configured to calculate life probability distribution, as the unreliability, covering efficiency and operational-function decay factors to equipment parts from material-life probability distribution covering deformation, cracks, oxidation, erosion and abrasion to become efficiency and operational-function decay factors and variation in probability of operational requirements including temperature and stress applied to the equipment parts, based on data stored in an efficiency and operational-function decay parameter assessment database constructed of data from the efficiency and operational-function decay parameter measurement unit and also experimentally-obtained and statistically-processed data on life affected by the efficiency and operational-function decay factors.

9. The apparatus for maintaining plant equipment according to claim 6, wherein the efficiency and operational-function decay unreliability calculation unit has an efficiency and operational-function decay unreliability function database constructed based on inspection and operation histories for the plant and other plants, the efficiency and operational-function decay unreliability calculation unit is configured to calculate the unreliability based on failure unreliability function on each event in the efficiency and operational-function decay-event tree in accordance with data on parts of the plant equipment and events input via the input unit, and also calculating unreliability of efficiency and operational-function decay factors based on the prediction by the efficiency and operational-function decay parameter assessment unit.

10. The apparatus for maintaining plant equipment according to claim 6, wherein the efficiency and operational-function decay prediction unit has an efficiency and operational-function measurement unit configured to measure equipment partial efficiency and plant total efficiency while monitoring at least a signal of in-plant fluid pressure, temperature, rotation speed, load, vacuum, in-liquid impurity density, cooling speed and time, deformation, displacement, decrease in wall thickness, fluid-level height and vibration, calculation results from the efficiency and operational-function decay unreliability calculation unit being adjusted based on measurement results from the efficiency and operational-function measurement unit, to predict efficiency and operational-function decay.

11. A method of maintaining plant equipment comprising the steps of:

receiving data on inspection, diagnosis, repair and operation histories for equipment that constitute a plant;

performing failure-event tree breakdown on failures to be expected for the equipment, thereby obtaining a failure-event tree;

predicting unreliability of at least one starting item in the failure-event tree;

calculating unreliability of each item in the failure-event tree based on a failure unreliability function;

multiplying each unreliability and a cost of recovery from each failure event in the failure-event tree and accumulating results of the multiplication in accordance with the tree breakdown, thus obtaining a recovery cost;

calculating preventive maintenance expenses for preventing failure events; and

deciding maintenance timing and technique through comparison between the recovery cost and the preventive maintenance expenses.

12. A method of maintaining plant equipment comprising the steps of:

receiving data on inspection, diagnosis, repair and operation histories for equipment that constitute a plant;

performing efficiency and operational-function decay event-tree breakdown on efficiency and operational-function decay factors to be expected for the equipment, thereby obtaining a efficiency and operational-function decay event-tree;

predicting unreliability of at least one starting item in the efficiency and operational-function decay event-tree;

calculating unreliability of each item in the efficiency and operational-function decay-event tree based on failure unreliability function;

calculating efficiency and operational-function decay to be expected from the calculation based on the failure unreliability function;

multiplying each unreliability and monetary loss due to efficiency and operational-function decay and a cost of recovery from the decay and accumulating results of the multiplication in accordance with the efficiency and operational-function decay-event tree breakdown;

calculating preventive maintenance expenses for preventing the efficiency and operational-function decay; and

deciding maintenance timing and technique through comparison between the recovery cost and the preventive maintenance expenses.